I may be missing something obvious, but it seems like you really don't need the conductive fabric if you can just have conductive glue... you can also cut back on sensor wires to a certain extent by just "drawing" the wire with the conductive glue.
That's kinda what I was trying to get at when I suggested the "silk screening" of the glue to form the sensors and interconnects..
BTW, fkeel - I noticed you are moving to customized forms using thermoplastic (Turbocast from Streifeneder, Apolit from Minke Props).
Whether or not it will help you (though it might help others, so you might want to reference it on your blog?), such plastic is known by a couple of different names in English:
"PolyMorph"
"Friendly Plastic"
...among others - its chemical name is:
Polycaprolactone (PCL) - Polycaprolactone - Wikipedia
One place I found that sells "bulk" (not sure if "to the public", though) is:
http://www.absorbables.com/standard.htm
They also have "sample kits". You can also find this plastic on Ebay quite often, typically sold as plastic for jewelry making; it comes in a wide variety of colors (including metallics). Standard forms I have seen (before seeing your samples), have been a flat "stick" form, and pellets.
In the US, I have seen it sold in craft stores, and the friendly plastic is available from Target stores.
